2011 FORD KUGA ALL

About This Manual
Introduction
This manual covers diagnosis and testing and
repair procedures.
It is structured into groups and sections, with
specific system sections grouped together under
their relevant group.
A group covers a specific portion of the vehicle.
The manual is divided into five groups, General
Information, Chassis, Powertrain, Electrical and
Body and Paint. The number of the group is the
first number of a section number.
Within Etis, the navigation tree will list the groups.
After selecting a group the navigation tree will then
list the sections within that group. Each section has
a contents list detailing Specifications, Description
and Operation, Diagnosis and Testing, General
Procedures, Disassembly and Assembly, Removal
and Installation.
References to LH (left-hand) and RH
(right-hand)
All LH and RH references to the vehicle are taken
from a position sitting in the driver seat looking
forward.
Vehicle LH and RH definition
E126780
12
Description
Item
LH
1
RH
2
All LH and RH references to the engine are taken
from a position at the flywheel looking towards the
crankshaft pulley.
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Powertrain LH and RH definition
E126781
1
2
3
4
Description
Item
front
1
right hand
2
rear
3
left hand
4
How to use Repair Procedures
This manual has been written in a format that is
designed to meet the needs of technicians
worldwide. It provides general descriptions for
accomplishing repair work with tested and effective
techniques.
Important Safety Instructions
Appropriate service methods and correct repair
procedures are essential for the safe and reliable
operation of all vehicles as well as the personal
safety of the individual carrying out the work.
Anyone who departs from the instructions provided
in this manual must first establish that personal safety or vehicle integrity is not compromised by
the choice of method, tools or components.
Warnings, Cautions and Notes in This
Manual
WARNING: Warnings are used to indicate
that failure to follow a procedure correctly
may result in personal injury.
CAUTION: Cautions are used to indicate
that failure to follow a procedure correctly
may result in damage to the vehicle or
equipment being used.
NOTE: Notes are used to provide additional
essential information required to carry out a
complete and satisfactory repair.
Generic warnings or cautions are in their relevant
description and operation procedure within section
100-00. If the generic warnings or cautions are
required for a procedure, there will be a referral to
the appropriate description and operation
procedure.
If a warning, caution or note only applies to one
step, it is placed at the beginning of the specific
step.
Global Authoring Standards (GAS) Repair
Procedures
NOTE: GAS style procedures can be identified by
steps that have no accompanying step text and
the magenta color of the electrical connectors and
fasteners such as nuts, bolts, clamps or clips.
A GAS removal and installation procedure uses a
sequence of color illustrations to indicate the order
to be followed when removing/disassembling or
installing/assembling a component.
Many of the GAS procedures will have the
installation information within the removal steps.
These procedures will have the following note at
the beginning of the procedure:
NOTE: Removal steps in this procedure may
contain installation details.
Reuse of fasteners and seals and gaskets
The following list details the general policy for the
reuse of fasteners and seals and gaskets.
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Types of self-locking nuts and bolts
NOTE:There are more types of self-locking fasteners available than shown in following illustration.
E126782
123
4567
Description
Item
Completely coated self-locking bolt
1
Partially coated self-locking bolt
2
Self-locking bolt with a locking washer
3
Self-locking nut with a plastic locking insert
4
Self-locking nut with thread deformation
(3 identations)
5
Self-locking nut with thread deformation
(to oval shape)
6
Self-locking nut with integrated locking ring
7
• All types of seals and gaskets must be discarded and new seals and gaskets installed
unless otherwise stated within the procedure.
• Nuts and bolts with a chemical coating for locking and/or sealing and/or antiseize must be
discarded unless the procedure advises to
reapply the coating with a specified material. • Nuts and bolts with a mechanical locking such
as thread inserts, thread deformation or locking
washers must be discarded and new nuts and
bolts installed unless otherwise stated within
the procedure.
• Torque to yield bolts must be discarded and new torque to yield bolts installed unless
otherwise stated within the procedure,
recognizable by a tightening torque with more
than one stage together with a torque angle.
Reuse of exterior trim parts
All type of glued exterior trim parts or parts
fastened with adhesive tape must be discarded
and new parts installed unless otherwise stated
within the procedure.
Specification data
Specification procedures will only contain technical
data that is not already part of a repair procedure.
Sequence of tasks
If components must be removed or installed in a
specific sequence, the sequence will be identified
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numerically in a graphic and the corresponding text
will be numbered accordingly.
Special Tools, Equipment, Materials and Torque
Figures
Special tools will be shown with the tool numbers
in the illustration. The special tool numbers, general
equipment, materials and torque figures used for
the procedure step will be shown in the text
column.
GAS Graphics
NOTE:Colors used in the graphic are as follows:
4
6
5
14
2
36
5
E141161
Description
Item
Blue - Target or primary component to be
removed/installed (or
disassembled/assembled).
1
Green - Components that need to be
removed prior to or installed after the
target/primary.
2
Description
Item
Brown - Components that need to be
removed prior to or installed after the
target/primary.
3
Yellow - Components to be set aside only,
that remains in the vehicle. Also
highlighted areas to inspect or adjust.
4
Magenta - Electrical connectors and
fasteners such as nuts, bolts, clamps, or
5
clips to be: detached, attached, loosened,
moved, removed or installed.
Pale Blue - Special tool(s), general
equipment, or common tools (used in an
uncommon way).
6
One illustration may have multiple steps assigned
to it.
Numbered pointers are used to indicate the number
of electrical connectors and fasteners such as nuts,
bolts, clamps and clips.
Items in the illustration can be transparent or use
cutouts to show hidden details.
E132042
x2
1
2
3
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E84836
308-640
Pointer symbols are used to draw attention to
components and give special instructions such as
a required sequence or number of components.
The number of components is reflected by the
value inside the luty arrow. A sequence number islocated inside the circle. Numbers inside circles
are also used to allocate special information such
as tightening torques or chemicals to a particular
component.
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Description
Item
Securing strap
5
File with a specified size
6
Center punch
7
Marker
8
Metal inert gas (MIG) welding equipment
9
Hose clamp
10
Interior trim remover
11
Vacuum cleaner
12
Strap wrench
13Description
Item
Wedge
14
Pin Punch
15
Air blow gun
16
Mallet
17
Relocate and support the component
18
Material symbols
The material symbols are used to show where to
use which type of material to carry out a procedure
step.
123
E88980
Description
Item
Remove/Install the specified blind rivet
1
Apply tape to the specified
component/area
2
Remove/Install the specified cable tie
3Miscellaneous symbols
These symbols provide further information that is
required to carry out a procedure step.
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Steering System Health and Safety Precautions
WARNINGS:
When handling the power steering fluid,
always wear protective goggles and gloves
made of nitril.
EYE CONTACT: Power steering fluid
contains long chain alkyl amine
thiophosphate. Avoid contact with the
eyes. Wash hands thoroughly after
handling. If power steering fluid comes into
contact with the eyes, flush the eyes with
plenty of cold running water for 15
minutes. Seek medical attention for any
persistent eye irritation or abnormality.
SKIN CONTACT: If power steering fluid
comes into contact with the skin, remove
contaminated clothing. Wash affected
areas of skin with soap and water. Seek
medical attention for any persistent skin
irritation or abnormality.
INHALED: If oil mist is inhaled, move a
victim to fresh air. Keep a victim warm and
at rest. Seek immediate medical attention
in cases of throat irritation or coughing.
SWALLOWED: Power steering fluid
contains long chain alkyl amine
thiophosphate. If swallowed, drink plenty
of water. Seek immediate medical attention.
CAUTION: If the power steering fluid is
spilled on the paintwork, the affected area
must be immediately washed down with
cold water.
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Exhaust Fumes
These contain asphyxiating, harmful and toxic
chemicals and particles such as carbon oxides,
nitrogen oxides, aldehydes, lead and aromatic
hydrocarbons. Engines should be run only under
conditions of adequate exhaust extraction or
general ventilation and not in confined spaces.
Gasoline (petrol) engine
There may not be adequate warning of odor or of
irritation before toxic or harmful effects arise. These
may be immediate or delayed.
Diesel engine
Soot, discomfort and irritation usually give
adequate warning of hazardous fume
concentrations.
Fibre Insulation
See alsoDusts.
Used in noise and sound insulation.
The fibrous nature of surfaces and cut edges can
cause skin irritation. This is usually a physical and
not a chemical effect.
Precautions should be taken to avoid excessive
skin contact through careful organization of work
practices and the use of gloves.
Fire
See also Welding,Foams,Legal Aspects.
Many of the materials found on or associated with
the repair of vehicles are highly flammable. Some
give off toxic or harmful fumes if burnt.
Observe strict fire safety when storing and handling
flammable materials or solvents, particularly near
electrical equipment or welding processes.
Make sure, before using electrical or welding
equipment, that there is no fire hazard present.
Have a suitable fire extinguisher available when
using welding or heating equipment.
First Aid
Apart from meeting any legal requirements it is
desirable for someone in the workshop to be
trained in First Aid procedures.
Splashes in the eye should be flushed carefully
with clean water for at least ten minutes.
Soiled skin should be washed with soap and water.
In case of cold burns, from alternative fuels, place
affected area in cool to cold water.
Individuals affected by inhalation of gases and
fumes should be removed to fresh air immediately.
If effects persist, consult a doctor.
If liquids are swallowed inadvertently, consult a
doctor giving him the information on the container
or label. Do not induce vomiting unless this action
is indicated on the label.
Fluoroelastomer
See Viton.
Foams - Polyurethane
See also Fire.
Used in sound and noise insulation. Cured foams
used in seat and trim cushioning.
Follow manufacturers instructions.
Unreacted components are irritating and may be
harmful to the skin and eyes. Wear gloves and
goggles.
Individuals with chronic respiratory diseases,
asthma, bronchial medical problems, or histories
of allergic diseases should not work in or near
uncured materials.
The components, vapors or spray mists can cause
direct irritation, sensitivity reactions and may be
toxic or harmful.
Vapors and spray mists must not be inhaled. These
materials must be applied with adequate ventilation
and respiratory protection. Do not remove the
respirator immediately after spraying; wait until the
vapors/mists have cleared.
Burning of the uncured components and the cured
foams can generate toxic and harmful fumes.
Smoking, naked flames or the use of electrical
equipment during foaming operations and until
vapors/mists have cleared should not be allowed.
Any heat cutting of cured foams or partially cured
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